RBI FUTERA XLF Series Installation And Operation Instructions Manual

Finned copper tube gas boilers (mb) & water heaters (mw)

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Page 1 XLF-I0M-2 82-0317 Finned copper tube Gas boilers (MB) & Water heaters (MW) Boiler manual Installation and operation instructions Also read and follow: XLF HeatNet Control manual Th is manual is intended only for use by a qualifi ed heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler.
Page 2: Power Entrance Box
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Futera -Series boilers — Overview XLF PRIMARY COMPONENTS Electrical enclosure (rear) Blower and motor Air inlet connection Flue outlet connection Gas entrance Boiler water return Boiler water supply Gas valve Power entrance box...
Page 3: Table Of Contents
This manual covers the application, installation, operation and BOILER/WATER HEATER LOCATION ... . 4 maintenance of a Futera XLF Series fi nned copper heating boiler/ water heater/pool heater. COMBUSTION AIR & VENTILATION ... . . 4 To obtain the safe, dependable, efficient operation and long life GENERAL VENTING GUIDELINES.
Page 4: Ratings & Capacities
RATINGS & CAPACITIES that would subject it to temperatures at or near freezing, Before undertaking the installation of the Futera XLF Series boiler/ see the “FREEZE PROTECTION” section on page 14. water heater check the rating plate to ensure that the unit has been sized Never store combustible materials, gasoline or any properly for the job.
Page 5: All Air From Inside The Building
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M All air from inside the building Table 2 Make-up Air Louver Sizing If the Futera XLF is to be located in a confi ned space, the minimum Input Required cross-sectional area clearances listed in Table 1, page 4 must be maintained between it...
Page 6: General Venting Guidelines
3 ft , 0.9 m intervals with overhead hangers. boiler installation. Close fi replace dampers. Th e certifi ed intake air terminal from RBI must be used, see Figure 1, 4. Place in operation the appliance being inspected. Follow the page 8, Figure 2, page 8 and Figure 4, page 9.
Page 7: Option 1: Direct Vent Positive Pressure
UL 1738 for installations in the United States, ULC S636 for installations in Canada. Th e certifi ed vent terminal from Combination direct vent systems RBI must also be used. Figure 4 (vent/air pipe equivalent lengths up to100 feet maximum) Th e maximum equivalent length for the horizontal vent pipe is 100 ft ,...
Page 8 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 1 VENT OPTION 1: DIRECT VENT — Horizontal air intake and venting for a single direct vent system Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table 3 or 4 for min. pipe diameters. W hen running horizontal combustion air and venting for single or multiple units, exhaust and combustion air terminals must...
Page 9 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 4 VENT OPTION 1: DIRECT VENT — Vertical air intake and venting for direct vent system Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table 3 or 4 for min. pipe diameters. Locate exhaust terminal from air intake downwind...
Page 10: Option 2: Vertical Venting Positive Pressure, Category Iv Figure 5 Or Figure 6 (Vent Pipe Equivalent Length Up To100 Feet Maximum)
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M lined and sized. Exterior masonry chimneys should not be used OPTION 2: VERTICAL VENTING unless properly lined to prevent condensation and draft problems. POSITIVE PRESSURE, CATEGORY IV Table 4 lists the equivalent breeching and fl ue sizes required for the boiler/water heater.
Page 11: Option 3: Side Wall Venting Positive Pressure
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M OPTION 3: SIDE WALL VENTING POSITIVE PRESSURE —CATEGORY IV FIGURE 7 “Combustion Air & Ventilation” section must be followed! Th e vent (VENT/AIR PIPE EQUIVALENT LENGTHS UP TO 100 FEET MAXIMUM) guidelines under the Horizontal Direct Vent Systems section must In this configuration the boiler/water heater blower is used also be followed.
Page 12: Option 4: Vertical Chimney Venting Negative
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M OPTION 4: VERTICAL CHIMNEY VENTING CATEGORY II CHIMNEY NEGATIVE PRESSURE — CATEGORY II INSPECTION & SIZING (MULTIPLE BOILERS WITH COMMON VENTING) Masonry chimneys, when used, must be lined with a metal liner certifi ed for Category IV venting.
Page 13 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 8 OPTION 4: VERTICAL CHIMNEY VENTING — Vertical venting — multiple-boiler installations See Table 5, page 12 for minimum riser diameter (dimension F) DO NOT common vent more than the following number of Futera XLF boilers: XLF-2500/3000 (4) boilers maximum.
Page 14: General Piping Requirements
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M GENERAL PIPING REQUIREMENTS Flow Switch Th e fl ow switch supplied with the boiler/water heater must be wired to the terminal strip in the control panel to prevent the boiler from Improper piping of this boiler/water heater will void fi ring unless there’...
Page 15 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M A temperature rise outside of the range listed in Table 7 Th e maximum allowable fl ow rate through a Futera will result in damage to the heat exchanger, voiding the XLF boiler is 260 GPM, 16.4 L/s when equipped with warranty! Th e maximum allowable temperature rise copper tubes.
Page 16: Low Water Cutoff
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Primary/secondary piping Table 7 Temperature Rise Table Boilers connected to heating systems using zone valves, zone pumps, Model ΔT = 20 ΔT = 11.1 or systems that have excessive fl ow rates or return water temperatures Number Flow Rate Pres.
Page 17 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 10 Typical Primary/Secondary Piping System (See Notes) NOTES: 1. Boiler circuit piping must be sized large enough to handle maximum fl ow through unit. 2.
Page 18 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 12 Low Temperature Piping (See Notes and Adjustment Procedures) H-3 Rev 5 Figure 13 Multiple Boiler Piping (See notes) These drawings show suggested piping con- fi guration and valving.
Page 19: Domestic Water Supply Piping
C will provide an increased quantity of 315 GPM, 19.9 L/s. See Table 9, page 20. tempered water and help prevent the growth of RBI water heaters are designed to run scale free. Due to water born bacteria. the extreme variables of water conditions world wide it is necessary to consider pH values and water hardness in relationship to scaling.
Page 20: Pump Requirements
In some areas of the country additional precautions must be observed due to unusual characteristics of the local water supply. Call the nearest RBI representative for details. To properly size the pump a grain hardness and pH test must be taken at the installation site before the order is placed.
Page 21 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 14 Typical Water Heating Piping (MW Models Only) (See Notes) Th ese drawings show sug- gested piping confi guration and valving. Check with local codes and ordinances for specifi c requirements.
Page 22: Gas Supply Piping
Th e Futera XLF comes from the factory ready to be piped to the gas supply. If for any reason the boiler/water heater is not for the type of gas available at the installation site, call your RBI representative to resolve the problem.
Page 23: Electrical Wiring
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M ELECTRICAL WIRING Table 11 Equivalent length (feet) for typical fi ttings Electrical power connections Pipe Fitting or valve size Label all wires prior to disconnection when servicing elbow Gate (branch fl ow)
Page 24: General Operation
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M GENERAL OPERATION WIRING & CONTROL SET-UP Before proceeding read and fully understand the instructions contained in this manual. Do not att empt Follow the instructions in the Futera XLF Control to operate this boiler/water heater if it has not been installation and operation instruction manual installed in accordance with the guidelines set forth in...
Page 25: Sequence Of Operation
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M SEQUENCE OF OPERATION Figure 17 HeatNet Control Panel NO DEMAND Standby 1. Th e boiler is idle with no interlocks in the fault condition. DEMAND Pre-Purge 1.
Page 26: Operating Instructions
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M b. Connect one side of a manometer or pressure gauge to the The following start-up procedure assumes that all water piping, gas piping and electrical connections manometer pressure port (barbed) on the pressure test manifold (located inside control panel).
Page 27 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Leave the manometer connected to the test manifold. Verify low fi re operation It will be needed for high fi re operation testing. 1. Connect a manometer or Magnehelic gauge with the pressure side to the manifold pressure port and the other to the manifold Verify high fi re operation reference port.
Page 28: To Turn Off Gas To Appliance
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M 6. If CO and pressure signal are correct, allow the boiler to reach CHECKING & ADJUSTMENTS steady state and verify supply gas pressure and check input rates as explained in the Gas Supply Piping section.
Page 29: Pilot Adjustment
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M If the gas pressure is above the limit in the table below, Pilot adjustment a lock-up style gas pressure regulator suitable for dead- 1. The pilot pressure has been factory set at 3 inches w.c., and end service, (such as an Equimeter or Fisher) must be shouldn't need adjustment.
Page 30: Maintenance
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M 3. Remove the front jacket panel and combustion chamber door. MAINTENANCE 4. Inspect the inside and outside of the heat exchanger Disconnect electrical power and close the manual gas for signs of damage, sooting or corrosion.
Page 31 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M 6. Replace the pipe plugs using a suitable thread sealant on each one. Figure 21 Main Burner Flame 7. Sagging or distorted heat exchanger tubes are an indication of low water fl ow through the system.
Page 32 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 23 Futera XLF pressure sensor hose routing...
Page 33: Repair Parts
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS Figure 24 Exploded view...
Page 34 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Figure 25 Figure 20 – Electrical components...
Page 35 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Top/Bottom X Profi le 04-0524 Middle X Profi le 04-0526 Top Y Profi le...
Page 36 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Manifold/Orifi ce Mounting Plate (Forward) 03-3734 03-3721 Manifold/Orifi ce Mounting Plate (Rear)
Page 37 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Combustion Chamber Rear/Side Panel 70-3566 70-3567 70-3568 70-3569...
Page 38 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Frequency Drive 15-0230 Flame Safeguard, RM7895C 16-0024R Spark Ignitor 16-0008...
Page 39 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Control Box Panel 70-3609 Collar Fan Transition 01-0201S Gasket 06-0004...
Page 40: Start-Up Report
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M START-UP REPORT DATE: JOB NAME: TECHNICIAN: LOCATION: COMPANY: MODEL: PHONE NUMBER: SERIAL #: PRE-STARTUP CHECK LIST ❑ NO VISIBLE DAMAGE TO UNIT ❑ INLET AIR FILTER INSTALLED AND CLEAN ❑...
Page 41 Finned copper tube gas boilers & water heaters – Boiler Manual & B l M COMBUSTION ANALYSIS MINIMUM FIRING RATE 100% FIRING RATE GAS PRESSURE AT ELBOW TEST PORT INCHES W.C. INCHES W.C. CO (PPM) NET STACK TEMPERATURE PRESSURE SIGNAL (Ps) INCHES W.C.
Page 42: Installation Requirements
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M NOTICE! Commonwealth of Massachusetts Installation Requirements MACODE-3 In the Commonwealth of Massachusett s, the installation approve the installation unless, upon inspection, the must be performed by a licensed plumber or gas fi tt er. inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 1.
Page 43: Limited Warranty
Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI.
Page 44: North Elm Street Westfi Eld, Ma
260 North Elm Street 7555 Tranmere Drive Westfi eld, MA 01085 Mississauga, Ontario L5S 1L4 Canada Phone: (413) 568-9571 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782 www.rbiwaterheaters.com Copyright 2008 Mestek, Inc.

This manual is also suitable for:

Futera xlf-series Futera xlf-2500 Futera xlf-3000